Onboard heater of auxiliary systems using exhaust gases and associated methods

ABSTRACT

An exhaust energy recovery system (EERS) and associated methods for an engine are disclosed. An embodiment of an EERS, for example, includes an inlet duct that is configured to divert exhaust gas from an exhaust duct of the engine into the recovery system and an outlet duct configured to return the exhaust gas to the exhaust duct downstream of the inlet duct. The recovery system is configured to heat components or fluids associated with engine to operating temperatures. The recovery system may be part of a mobile power system that is mounted to a single trailer and includes an engine and a power unit such as a high pressure pump or generator mounted to the trailer. Methods of operating and purging recovery systems are also disclosed.

PRIORITY CLAIM

This is a divisional of U.S. Non-Provisional application Ser. No.17/383,900, filed Jul. 23, 2021, titled “ONBOARD HEATER OF AUXILIARYSYSTEMS USING EXHAUST GASES AND ASSOCIATED METHODS,” which is acontinuation of U.S. Non-Provisional application Ser. No. 15/929,715,filed May 18, 2020, titled “ONBOARD HEATER OF AUXILIARY SYSTEMS USINGEXHAUST GASES AND ASSOCIATED METHODS,” now U.S. Pat. No. 11,428,165,issued Aug. 30, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 62/704,556, filed May 15, 2020, titled“ONBOARD HEATER OF AUXILIARY SYSTEMS USING EXHAUST GASES AND ASSOCIATEDMETHODS,” the disclosures of which are incorporated herein by referencein their entireties.

TECHNICAL FIELD

The present disclosure generally relates to systems for energy recoveryfrom exhaust engines and methods thereof. More specifically, the energyrecovery systems may be used to recover heat from the exhaust of gasturbine engines. The systems and methods of the present disclosure maybe used and implemented onboard a mobile fracturing trailer.

BACKGROUND OF THE DISCLOSURE

Hydraulic fracturing often is used to produce oil and gas in an economicmanner from low permeability reservoir rocks, such as shale. Hydraulicfracturing restores or enhances productivity of a well by creating aconductive flow path of hydrocarbons between the reservoir rock and awellbore. During hydraulic fracturing, a fluid initially is pumped underhigh pressure to fracture rock in a reservoir formation and open a flowchannel. Thereafter, a proppant-carrying fluid, e.g., a fluid thatcomprises proppant in the form of granular solid and/or semi-solidcomponents, e.g., sand, ceramics, is pumped to continue opening andwidening the flow channel while suspending proppant inside it. Theproppant, thus, keeps the flow path opened for the hydrocarbons to flow.

Hydraulic fracturing treatments may be performed using high powered gasturbine engines that power fracturing pumps to deliver fluids at a highpressure, specifically, above the fracture pressure of the rock in areservoir formation.

High powered gas turbine engines have been used as power sources for avariety of industrial applications. During the use of high powered gasturbine engines, the exhaust system is an integral part of the designand operation of a successful turbine system. The primary working mediafor a gas turbine engine is air, and specifically, the mass flow of airinto turbine engine inlet ducts must be expelled through the exhaustsystem. The exhaust systems must be designed to provide minimal backpressure on turbine exhaust ducts while also allowing the diffuser toreduce the velocity of the exhaust gases and increase a static pressure.Exhaust stack gases carry mass amounts of energy mostly identified inheat where temperatures of over 1000 degrees Fahrenheit are commonlyfound.

SUMMARY OF THE DISCLOSURE

While the turbine is expelling mass amounts of heat, portions of a gasturbine engine and other systems mounted to a fracturing trailer, forexample, may benefit from being heated or pre-heated to an operatingtemperature before use. For example, oil used to lubricate a gear box ora fracturing pump may benefit from being at an operating temperaturebefore being used in the gearbox or fracturing pump, respectively.

Embodiments of this disclosure relates to an exhaust energy recoversystem that is mounted to a mobile platform with an engine and isconfigured to recover energy in the form of heat from the exhaust gasesof the engine. In addition, embodiments of this disclosure relates tomethods of operating the exhaust energy recovery system and methods ofcleaning or purging exhaust energy recover systems.

In accordance with an embodiment of the present disclosure, a mobilepower system includes a transportation platform, an engine, a first heatdistribution element, and an exhaust energy recovery system. Thetransportation platform may be a single trailer, for example. The engineis mounted to the transportation platform and includes an intake portand an exhaust duct. The engine may be a gas turbine engine and, morespecifically, may be a dual-fuel dual-shaft gas turbine engine. Thefirst heat distribution element is mounted to the transportationplatform. The exhaust energy recovery system is mounted to thetransportation platform and includes an inlet duct, an outlet duct, anda first heat exchanger. The inlet duct is positioned in communicationwith the exhaust duct and has an open configuration in which the inletduct is configured to divert a first portion of exhaust gas from theexhaust duct into a recovery flow path and allow a second non-zeroportion of the exhaust gas of the exhaust duct to be exhausted. Theinlet duct also has a closed configuration in which the inlet duct isconfigured to prevent exhaust gas from flowing into the recovery flowpath. The outlet duct in communication with the exhaust duct downstreamof the inlet duct and is configured to return the first portion of theexhaust gas from the recovery flow path to the exhaust duct. The firstheat exchanger is disposed in the recovery flow path between the inletduct and the outlet duct. The first heat exchanger is associated withthe first heat distribution element. The first heat exchanger isconfigured to receive exhaust gas from the recovery flow path, transferheat from the received exhaust gas to fluid of the first heatdistribution element within the first heat exchanger, and return thereceived exhaust gas to the recovery flow path.

In some embodiments, the exhaust energy recovery system includes aflushing system that is in communication with the recovery flow path.The flushing port, for example, may be configured to receive water suchthat the water flows through the recovery flow path and exits the outletduct to purge residue from the recovery flow path.

In another embodiment of the present disclosure, an exhaust energyrecovery system includes an inlet duct, an outlet duct, and a first heatexchanger. The inlet duct is positioned in communication, i.e., fluidflow communication, with an exhaust flow path. The inlet duct has anopen configuration in which the inlet duct is configured to divert afirst portion of the exhaust gas from the exhaust flow path to arecovery flow path and a low or a second non-zero portion of the exhaustgas of the exhaust flow path to be exhausted. The inlet duct also has aclosed configuration in which the inlet duct is configured to preventexhaust gas from flowing the recovery flow path. The outlet duct ispositioned in communication with the exhaust flow path downstream of theinlet duct. The outlet duct is configured to return the first portion ofthe exhaust gas from the recovery flow path to the exhaust flow path.The first heat exchanger is disposed in the recovery flow path betweenthe inlet duct and the outlet duct. The first heat exchanger isconfigured to receive exhaust gas from the recover flow path, transferheat from the received exhaust gas to fluid within the first heatexchanger, and return the received exhaust gas to the recovery flowpath.

In some embodiments, the exhaust energy recovery system includes aflushing port that is in communication with the recovery flow path. Theflushing port is configured to receive water such that the water flowsthrough the recovery flow path and exits the outlet duct to purgeresidue from the recovery flow path.

In another embodiment of the present disclosure, a method of recoveringenergy from exhaust gases of a gas turbine engine of a mobile powersystem includes operating the gas turbine engine mounted to a trailerand opening an inlet duct that is disposed in the exhaust duct to diverta portion of exhaust gas flowing form an exhaust duct of the engine toan exhaust energy recovery system mounted to the trailer. The divertedexhaust gas flows through a first heat exchanger of the exhaust energyrecovery system to transfer heat from the exhaust gas to fluid of afirst heat distribution element mounted to the trailer, and the exhaustgas is returned to the exhaust duct of the engine via an outlet duct ofthe exhaust energy recovery system that is in communication with ordisposed within the exhaust duct downstream of the inlet duct.

In embodiments, the method also may include flushing the exhaustrecovery system. The flushing, for example, in turn, may includeverifying that the inlet duct is closed and injecting water into aflushing port such that the water flows through the exhaust energyrecovery system and into the exhaust duct via the outlet duct to purgethe exhaust energy recovery system.

Those skilled in the art will appreciate the benefits of variousadditional embodiments reading the following detailed description of theembodiments with reference to the below-listed drawing figures. It iswithin the scope of the present disclosure that the above-discussedaspects be provided both individually and in various combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

FIG. 1 is a perspective view of an exemplary mobile power systemprovided in accordance with the present disclosure.

FIG. 2 is a schematic view of an exemplary engine of the mobile powersystem of FIG. 1 according to an embodiment of the present disclosure.

FIG. 3 is a schematic view of an exemplary exhaust energy recoverysystem according to an embodiment of the present disclosure.

FIG. 4 is a schematic view of a heat exchanger of the exhaust energyrecovery system of FIG. 3 according to an embodiment of the presentdisclosure.

FIG. 5 is a flowchart of a method of operating an exhaust energyrecovery system according to an embodiment of the present disclosure.

FIG. 6 is a flowchart of a method of purging an exhaust energy recoverysystem according to an embodiment of the present disclosure.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to example embodiments thereof with reference to the drawingsin which like reference numerals designate identical or correspondingelements in each of the several views. These example embodiments aredescribed so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Features from one embodiment or aspect may be combined withfeatures from any other embodiment or aspect in any appropriatecombination. For example, any individual or collective features ofmethod aspects or embodiments may be applied to apparatus, product, orcomponent aspects or embodiments and vice versa. The disclosure may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification and the appended claims, thesingular forms “a,” “an,” “the,” and the like include plural referentsunless the context clearly dictates otherwise. In addition, whilereference may be made herein to quantitative measures, values, geometricrelationships or the like, unless otherwise stated, any one or more ifnot all of these may be absolute or approximate to account foracceptable variations that may occur, such as those due to manufacturingor engineering tolerances or the like.

The embodiments of the present disclosure are directed to mobile powersystems, for example, mobile power systems that are mounted to atransportation platform that are transportable on and off highways. Inparticular, embodiments of the present disclosure are directed to energyrecovery systems that are mounted to a transportation platform with amobile power system to distribute, recover, and reuse heat energy fromexhaust of the mobile power system. Some embodiments of the presentdisclosure are directed to energy recovery systems that are mounted tohydraulic fracturing pumpers. as will be understood by those skilled inthe art.

FIG. 1 illustrates an exemplary mobile power system 100 is provided inaccordance with an embodiment of the present disclosure. The exemplarymobile power system 100 includes transportation platform 110, an engine120, a power unit 140, and an exhaust energy recovery system 10. Thetransportation platform 110 is shown as a single trailer with the entiremobile power system 100 and components thereof mounted thereto. Forexample, it may be advantageous to have the entire mobile power system100 mounted to a single trailer such that setup and startup of themobile power system 100 does not require onsite assembly of the mobilepower system 100. In addition, mounting the entire mobile power system100 to a single trailer may decrease a footprint of the mobile powersystem 100. The transportation platform 110 may be a trailer that may bepulled by a tractor (not shown) on and off public highways. In someembodiments, the transportation platform may include more than onetrailer.

The engine 120 is mounted to the transportation platform 110 and may beany suitable engine including, but not limited to, an internalcombustion engine or a gas turbine engine. The engine 120 may be asingle fuel engine operating on gasoline, natural gas, well gas, fieldgas, diesel, or other suitable fuel. In some embodiments, the engine 120may be a dual fuel engine operating on a liquid fuel and a gaseous fuel.In certain embodiments, the engine 120 is a dual fuel gas turbine enginethat operates on diesel fuel, e.g., #2 diesel as will be understood bythose skilled in the art, and on a gaseous fuel, e.g., natural gas, wellgas, or field gas. In particular embodiments, the engine 120 is a dualfuel, dual shaft gas turbine engine that operates on a liquid fuel suchas diesel fuel and a gaseous fuel such as natural, well gas, or fieldgas.

The engine 120 is operably coupled to the power unit 140 such that theengine 120 drives the power unit 140 to supply power to a systemexternal of the mobile power system 100. As shown, the power unit 140 isa high pressure pump, such as those that include hydraulic fracturingpumps, that is configured to supply power in the form of high pressurefluid. The power unit 140 may be a high pressure single actingreciprocating pump or a high pressure centrifugal pump. In certainembodiments, the power unit 140 may be a generator configured to produceelectric power. The engine 120 may be operably coupled to the power unit140 by a gearbox (not explicitly shown). The gearbox may decrease aspeed of an input from the engine 120 while increasing a torque orincrease the speed of an input from the engine 120 while decreasing atorque. In some embodiments, the gearbox is a transmission that allowsfor adjustment of the ratio between a speed of rotation of the inputfrom the engine 120 to a speed of rotation of the power unit 140. Incertain embodiments, the transmission has a set number of speed ratios.In particular embodiments, the transmission is continuously variablethrough a wide range of speed ratios.

FIG. 2 illustrates a schematic of an exemplary engine 120 shown as adual-shaft gas turbine engine. The engine 120 includes an intake 122, anaxial compressor 124, a radial compressor 125, a combustion chamber 126,a producer turbine 127, a power turbine 128, and an exhaust duct 129 aswill be understood by those skilled in the art. As air moves through thecompressors 124, 125 from the intake 122 to the combustion chamber 126,the pressure of the air is increased. As the air moves through thecombustion chamber 126, fuel is mixed with the air and ignited such thatthe temperature of the air is increased. As the air flows through theproducer and power turbines 127, 128 the pressure of the air isdecreased as the air rotates the turbines 127, 128. The air continuesthrough engine 120 and out the exhaust duct 129 to be released to theenvironment.

FIG. 3 , in turn, illustrates a schematic of an exemplary exhaust energyrecovery system (EERS) 10 in accordance with an embodiment of thepresent disclosure. The EERS 10 is configured to draw a portion of theair from the exhaust duct 129 in the form of exhaust gas and to recoverenergy from the exhaust gas to heat one or more components or systems onthe transportation platform (FIG. 1 ) and return the exhaust gas to theexhaust duct 129. The EERS 10 defines a recovery flow path that in orderof downstream gas flow includes an inlet duct 20, a gas supply line 12,one or more heat exchangers 72, 74, 76, 78, a gas return line 19, and anoutlet duct 90.

The inlet duct 20 is disposed within the exhaust duct 129 and isconfigured to draw a portion of exhaust gas flowing out of the exhaustduct 129 into the gas supply line 12. The inlet duct 20 is sized to drawa portion of the exhaust gas flowing out of the exhaust duct 129 whileminimally or negligibly increasing backpressure within the exhaust duct129. The inlet duct 20 may protrude into the exhaust duct 129, or theinlet duct 20, for example, also may be an opening in a wall definingthe exhaust duct 129. The inlet duct 20 may include an inlet valve 22positioned at or downstream of the inlet duct 20 within the gas supplyline 12. The inlet valve 22 is configured to open the inlet duct 20 todraw exhaust gas into the gas supply line 12 or close the inlet duct 20to prevent exhaust gas from flowing into the gas supply line 12. Theinlet valve 22 may have an open position, a closed position, and may beadjustable to one or more discrete position between the open and closedpositions. The inlet valve 22 may include a mechanical linkage foropening and closing the inlet duct 20. In particular embodiments, theinlet valve 22 may open the inlet duct 20 by extending the inlet duct 20into the exhaust duct 129 and close the inlet duct 20 by withdrawing theinlet duct 20 from the exhaust duct 129. In some embodiments, the inletvalve 22 may be a one-way valve that is configured to prevent backflowthrough the gas supply line 12 into the exhaust duct 129 through theinlet duct 20.

The gas supply line 12 may include a check valve 24 positioneddownstream of the inlet duct 20 and/or the inlet valve 22 that preventsbackflow through the gas supply line 12, e.g., flow towards the inletduct 20. The check valve 24 may be a poppet valve or a ball and metalseat valve. Seals within the check valve may be metal to metal sealssuch that the check valve 24 is rated for temperatures at or above 900°F. Exemplary check valves are available from SSP Corporation ofTwinsburg, Ohio, as will be understood by those skilled in the art.

The gas supply line 12 continues from the inlet duct 20, the inlet valve22, or check valve 24 towards one or more heat exchangers 72, 74, 76,78. Between the inlet duct 20 and the heat exchangers 72, 74, 76, 78,the EERS 10 may include a flow restrictor 30. The flow restrictor 30 isconfigured to regulate an amount of exhaust gas within the gas supplyline 12 downstream of the flow restrictor 30. The flow restrictor 30 maylimit the pressure of exhaust gas flowing through the flow restrictor 30to a maximum operating pressure. The maximum operating pressure may bein a range of 80 to 125 pounds per square inch in gauge (PSIG), forexample. The flow restrictor 30 may be a Habonim like valve, forexample, as will be understood by those skilled in the art. An exemplaryflow restrictor is available from Watson McDaniel of Pottstown, Pa., aswill be understood by those skilled in the art.

The gas supply line 12 may include a pressure gauge 26 upstream of theflow restrictor 30 and/or may include a pressure gauge 28 downstream ofthe flow restrictor 30. The pressure gauges 26, 28 may provide apressure to one or more control systems of the EERS 10, e.g., EERScontroller 14. For example, downstream of the flow restrictor 30 andupstream of the heat exchangers 72, 74, 76, 78, the EERS 10 may includea pressure relief valve 40 that is in communication on an upstream sidewith the gas supply line 12 and on a downstream side with the gas returnline 19. The pressure relief valve 40 may be configured to open when apressure within the gas supply line 12 is greater than a predeterminedpressure or to prevent fluid from flowing through the gas supply line 12downstream of the pressure relief valve 40 as described in greaterdetail below. For example, the pressure relief valve 40 may be incommunication with the pressure gauge 28 and configured to open when thepressure gauge measures a pressure greater than a predeterminedpressure. The pressure relief valve 40 may be a one-way valve to preventflow from the gas return line 19 into the gas supply line 12.

As further illustrated in FIG. 3 , the EERS 10 may include a manifold 50positioned downstream of the pressure relief valve 40. The manifold 50receives the gas supply line 12 and provides separate gas supply paths52, 54, 56, 58 to the heat exchangers 72, 74, 76, 78. The manifold 50allows for selective distribution of exhaust gas from the gas supplyline 12 to the heat exchangers 72, 74, 76, 78. The gas supply paths 52,54, 56, 58 are similar to one another. As such, only the first gassupply path 52 will be described for brevity.

The first gas supply path 52 extends from an upstream end that is incommunication with the manifold 50 to the first heat exchanger 72 whichis in communication with the downstream end thereof. The first gassupply path 52 includes a control valve 62 disposed between the upstreamand downstream ends thereof. The control valve 62 has an openconfiguration in which the control valve 62 allows exhaust gas to flowthrough the first gas supply path 52 from the manifold 50 and into thefirst heat exchanger 72 and has a closed configuration in which thecontrol valve 62 prevents exhaust gas from flowing through the first gassupply path 52 from the manifold 50. The control valve 62 may be athermostatically controlled control valve, as will be understood bythose skilled in the art, that includes temperature sensor configured tomeasure a temperature of a heat distribution element of the mobile powersystem 100, e.g., an oil reservoir, gas reservoir, fuel reservoir. Insome embodiments, the heat distribution element may be disposed in therecovery flow path between the inlet duct 20 and the outlet duct 90. Asshown, the control valve 62 is associated with a first heat distributionelement (e.g., a reservoir of lubrication oil 142) for the power unit140 (FIG. 1 ) and includes a temperature probe or sensor disposed withinthe reservoir 142. The control valve 62 may be configured to open inresponse to the temperature sensor indicating a temperature within thereservoir 142 is at or below a first predetermined temperature and maybe configured to close in response to the temperature sensor indicatinga temperature within the reservoir 142 is at or above a secondpredetermined temperature. The second predetermined temperature may bean operating temperature of the lubrication oil. The control valve 62may have a plurality of open positions to control a flow of exhaust gasthrough the control valve 62 when the temperature sensor indicates atemperature within the reservoir 142 is between the first and secondpredetermined temperatures. In some embodiments, the control valve 62may be in communication with the EERS controller 14 such that thecontrol valve 62 may be opened and/or closed in response to signals fromthe EERS controller 14. When the control valve 62 is open, exhaust gasflows through the gas supply path 52 into the heat exchanger 72 whereheat from the exhaust gas is transferred to a media to be heated, e.g.,lubrication oil in the reservoir 142.

The pressure relief valve 40 and/or the control valves 62, 64, 66, 68may be metal seated valves capable of operating with the hightemperature exhaust gas. The control valves 62, 64, 66, 68 may have anorifice size of less than 3/32 of an inch and the pressure relief valve40 may have an orifice in a range of 7/64 to ¼ of an inch. Exemplarilyvalves are available from High Pressure Equipment of Erie, Pa. andAutoclave Engineers of Erie, Pa., as will be understood by those skilledin the art.

FIG. 4 illustrates an exemplary heat exchanger 72 in accordance with anembodiment of the present disclosure. The heat exchanger 72 may be ashell and tube heat exchanger, for example, that includes a shell 170and a plurality of tubes 171 that extend through a cavity 173 defined bythe shell 170. The cavity 173 is defined within the shell 170 betweenend plates 179. The tubes 171 extend between the end plates 179 tointerconnect chambers or plenums on either side of cavity 173. The shell170 includes a gas inlet 172, a gas outlet 174, a media inlet 176, and amedia outlet 178. The gas inlet 172 receives exhaust gas from the gassupply path 52 (FIG. 3 ) such that the exhaust gas flows through thecavity 173 and exits the gas outlet 174 into a gas return path 92 suchthat the exhaust gas is returned to the gas return line 19. The cavity173 may include one or more baffles 175 that create a tortured path oran extended path within the cavity 173 to increase a duration theexhaust gas is within the cavity 173. The media inlet 176 flows into aplenum positioned along one side of the cavity such that the media flowsthrough the cavity 173 within the tubes 171 to the plenum on the otherside of the cavity 173 and exits through the media outlet 178. When themedia is within the tubes 171, the media receives heat from the exhaustgas flowing through the cavity 173. In some embodiments, the media mayflow through the cavity 173, and the exhaust gas may flow through thetubes 171. While the heat exchanger 72 is illustrated as a shell andtube heat exchanger, other types of heat exchangers may also be used aswill be understood by those skilled in the art.

The heat exchangers 72, 74, 76, 78 may be a shell and tube heatexchanger as shown in FIG. 4 . Additionally or alternatively, the heatexchangers 72, 74, 76, 78 may include a heat fan that blows acrossheating coils towards a reservoir such that the reservoir receives heatfrom the heat exchanger. The heat exchangers 72, 74, 76, 78 may beassociated with a variety of heat distribution elements of the mobilepower system 100 including, but not limited to, the first heatdistribution element (e.g., the reservoir of lubrication oil 142) of thepower unit 149, a second heat distribution element (e.g., a reservoir oflubrication oil 132 (FIG. 3 )) for the gear box, a fuel line, or a fuelreservoir.

Also, as shown in FIG. 3 , the gas return paths 92, 94, 96, 98accumulate into the gas return line 19 such that exhaust gas from theheat exchangers 72, 74, 76, 78 is returned to the exhaust duct 129 viathe outlet duct 90. The outlet duct 90 is disposed within the exhaustduct 129 downstream of the inlet duct 20. The gas return paths 92, 94,96, 98 and the gas return line 19 may have one or more check valves (notshown) that allow flow downstream towards the exhaust duct 129 andprevent backflow upstream towards the heat exchangers 72, 74, 76, 78.Returning the exhaust gas to the exhaust duct 129 allows for a singlepoint of exhaust for the mobile power system 100 (see, e.g., FIG. 1 ).

In embodiments of the disclosure, the EERS 10 may include a cleaning andflushing system 80 that is configured to clean the EERS 10 and to purgethe EERS 10 of residue and/or particulates that may accumulatetherewithin. The flushing system 80 may include a flushing port 82 and acheck valve 84. The flushing port 82 is configured to receive a cleaningliquid, e.g., water, cleaning agent, or combinations thereof, such thatthe cleaning liquid may be distributed through the EERS 10 to clean orto purge the EERS 10. For example, the cleaning liquid may be injectedinto the EERS 10 via the flushing port 82. The check valve 84 is similarto the other check valves detailed herein, e.g., check valve 24, thatpermit flow in the EERS 10 downstream while preventing backflow withinthe EERS 10. The flushing port 82 and/or the check valve 84 may be incommunication with the EERS controller 14.

FIG. 5 illustrates an embodiment of a method of heating components of asystem with energy recovered from exhaust gases in accordance with thedisclosure, and with reference to the mobile power system 100 of FIG. 1and the EERS 10 of FIG. 3 is referred to generally as method 200. In aninitial or shutdown configuration, the inlet duct 20, the pressurerelief valve 40, and the control valves 62, 64, 66, 68 of the EERS 10are in a closed position such that gas or fluid flow within the EERS 10is prevented (Step 210). When the engine 120 is running, the EERScontroller 14 monitors temperatures or receives signals includingtemperatures of components or fluid reservoirs of the mobile powersystem 100 that are associated with the EERS 10, e.g., the lubricationreservoir 142 of the power unit 140, a lubrication reservoir 132 of thegearbox (Step 212). When the temperatures of one or more of thecomponents or fluid reservoirs is below a predetermined minimumtemperature for the particular component or fluid reservoir, e.g., thelubrication reservoir 142, the EERS controller 14 opens the inlet duct20 such that a portion of the exhaust gas exiting the engine 120 throughthe exhaust duct 129 is diverted into the gas supply line 12 (Step 220).It will be appreciated that only a portion of the exhaust gases of theexhaust duct 129 is diverted with a non-zero portion of the exhaustgases continuing past the inlet duct 20. In some embodiments, the EERS10 diverts a range of 0.5% to 20% of the exhaust gas from the exhaustduct 129.

When the inlet duct 20 is open, exhaust gas flows into the gas supplyline 12 to the manifold 50. The EERS controller 14 may provide a signalto one or more of the control valves 62, 64, 66, 68 associated with acomponent or reservoir that is below a respective minimum temperaturesuch that exhaust gas flows from the manifold 50 into a gas supply path52, 54, 56, 58 associated with the respective control valve 62, 64, 66,68 (Step 230). In certain embodiments, the control valves 62, 64, 66, 68receive temperature signals from a temperature sensor associated withthe respective component or reservoir and open in response to the signalfrom the associated temperature sensor independent of a signal from theEERS controller 14. In particular embodiments, the control valves 62,64, 66, 68 may be controlled by the EERS controller 14 and independentof the EERS controller 14. The EERS controller 14 and/or the controlvalves 62, 64, 66, 68 may open multiple control valves 62, 64, 66, 68simultaneously such that exhaust gas flows through multiple gas supplypaths 52, 54, 56, 58 simultaneously. When a respective control valve 62,64, 66, 68 is open, exhaust gas flows through the respective gas supplypath 52, 54, 56, 58 and heat exchanger 72, 74, 76, 78 such that theexhaust gas transfers a heat into a media of the respective heatexchanger 72, 74, 76, 78 such that a temperature of the media isincreased or heated. Heating the media with the heat exchanger 72, 74,76, 78 may preheat the media before use in the mobile power system 100.For example, the heat exchanger 72 may heat a lubrication of the powerunit 140 such that the lubrication is preheated before being provided tothe power unit 140. In some embodiments, the lubrication is preheated toan operating temperature before being provided to the power unit 140. Inaddition, the heat exchanger 74 may heat a lubrication of the gearboxsuch that the lubrication is preheated before being provided to thegearbox. Preheating lubrication may increase a life of the componentlubricated by the lubricant and/or extend the life of the lubricant.Increasing the life of a component or the lubricant may increase an inservice time of the mobile power system 10 and/or reduce costsassociated with operating the mobile power system 10.

From the heat exchangers 72, 74, 76, 78, the exhaust gas flows throughthe respective gas return path 92, 94, 96, 98 and into the gas returnline 19. The gas return line 19 terminates in the outlet duct 90 thatreleases the exhaust gas from the EERS 10 back into the exhaust duct 129downstream of the inlet duct 20.

One or more of the control valves 62, 64, 66, 68, the EERS controller 14and/or the control valves 62, 64, 66, 68 may monitor a temperature ofthe components and/or reservoirs receiving exhaust gas. When atemperature of one of the components and/or reservoirs reaches arespective maximum temperature, the EERS controller 14 sends a signal tothe respective control valve 62, 64, 66, 68 to close (Step 240). In someembodiments, the respective control valves 62, 64, 66, 68 receives asignal from a temperature sensor indicative of the maximum temperatureand closes in response to the signal. The maximum temperature may be adesired operating temperature of the components and/or liquids withinthe reservoirs.

When the inlet duct 20 is open, the EERS controller 14 and/or thepressure relief valve 40 receives signals indicative of the pressurewithin the gas supply line 12 (Step 250). For example, the EERScontroller 14 may receive signals from the pressure sensor 26 and/orpressure sensor 28 to measure a pressure within the gas supply line 12.In some embodiments, the pressure relief valve 40 may receive signalsfrom the pressure sensors 26, 28 indicative of the pressure within thegas supply line 12. When the pressure within the gas supply line 12exceeds a predetermined maximum pressure, the pressure relief valve 40opens such that exhaust gas bypasses the manifold 50 and passes to thegas return line 19 (Step 254). In some embodiments, when the pressurerelief valve 40 is open, exhaust gas flows through the gas supply line12 into the manifold 50 and flows through the pressure relief valve 40to the gas return line 19. When the pressure within the gas supply line12 drops below a predetermined pressure, the pressure relief valve 40closes such that the exhaust gas passes from the gas supply line 12 tothe manifold 50 (Step 256).

When all of the control valves 62, 64, 66, 68 are closed in response tothe temperatures of all of the components and reservoirs being atoperating levels such that additional heat from the EERS 10 is notrequired, the EERS controller 14 may provide a signal to the inlet valve22 to close the inlet duct 20 (Step 260). When the inlet duct 20 isclosed, the exhaust gas within the EERS 10 may be released by cyclingthe pressure relief valve 40 and/or the control valves 62, 64, 66, 68 toan open position and then the closed position thereof to evacuate anyremaining exhaust gas from the EERS 10 (Step 264). When the inlet duct20, the pressure relief valve 40, and the control valves 62, 64, 66, 68are in the closed position, the EERS 10 is returned to the initial orshutdown configuration.

FIG. 6 illustrates a method of cleaning or purging the EERS 10 inaccordance with an embodiment of the disclosure with reference to theEERS 10 of FIG. 3 and is referred to generally as method 300. The method300 may be performed to remove residue in the form of particulates orother matter from the EERS 10. When the EERS 10 is in the shutdownconfiguration, a liquid source is connected to the flushing port 82 toprovide or inject liquid into the EERS 10 (Step 310). The EERScontroller 14 may receive a signal from the flushing port 82 indicativeof a liquid source being connected or may receive user input to enterinto a purge cycle (Step 314). As the EERS controller 14 begins thepurge cycle, the EERS controller 14 may verify that a temperature withinthe EERS 10 is below a predetermined temperature (Step 312). Forexample, the EERS controller 14 may verify temperatures at each of thecomponents or reservoirs to verify that the temperature of each is belowa predetermined temperature. The predetermined temperature may be in arange of 40° F. and 150° F., for example. The EERS controller 14 mayprevent liquid from entering the EERS 10 until the EERS 10 is below apredetermined temperature.

When the EERS 10 is below a predetermined temperature, liquid flowingthrough the flushing port 82 enters the gas supply line 12 (Step 320).With liquid within the gas supply line 12, the EERS controller 14 opensthe control valves 62, 64, 66, 68 to flow fluid through each of the heatexchangers 72, 74, 76, 78 (Step 330). The EERS controller 14 may openthe control valves 62, 64, 66, 68 simultaneously or may sequentiallyopen and close the control valves 62, 64, 66, 68. In some embodiments,the EERS controller 14 may pulse one or more of the control valves 62,64, 66, 68 to purge the gas supply paths 52, 54, 56, 58, the controlvalves 62, 64, 66, 68, and heat exchanges 72, 74, 76, 78. The EERScontroller 14 also opens the pressure relief valve 40 to purge thepressure relief valve 40 (Step 340). The EERS controller 14 may pulsethe pressure relief valve 40 between the open and closed positions. Thepulsing of the control valves 62, 64, 66, 68 and/or the pressure valve40 may increase an efficacy of the fluid purging the EERS 10. The EERScontroller 14 may open the control valves 62, 64, 66, 68 simultaneouslyor sequentially with the pressure relief valve 40.

The fluid that enters the EERS 10 through the flushing port 82 flowsthrough the EERS 10 and exits the gas return line 19 through the outletduct 90 into the exhaust duct 129 of the engine 120. The engine 120 maybe operating when the method 300 is run such that the fluid exiting theoutlet duct 90 is liquefied by exhaust gas of the engine 120. In someembodiments, the method 300 is performed when the engine 120 is notoperating. In such embodiments, the method 300 may include recoveringthe fluid used to flush the EERS 10 (Step 350).

An embodiment of the flushing port 82 and an embodiment of the method300 of purging the EERS 10 may be advantageous, for example, when theengine 120 is a dual-fuel turbine or when a fuel of the turbine createsparticulates in the exhaust gas. For example, when a gas turbine is runon #2 diesel fuel, the exhaust gas may include particulates that maydecrease the efficiency or clog components of the EERS 10. A clog in theEERS 10 may increase backpressure within the EERS 10 and ultimately theexhaust duct 129. As such, purging or cleaning the EERS 10, as detailedwith respect to method 300, may increase the efficiency of the EERS 10and/or reduce downtime of the EERS 10 for maintenance and cleaning aswill be understood by those skilled in the art.

The components of the EERS 10 detailed above that are come into contactwith the exhaust gases including, but not limited to, lines, paths,valves, manifold, heat exchangers, seals, and ducts, as will beunderstood by those skilled in the art, are required to be rated totemperatures greater than anticipated temperatures of the exhaust gases,e.g., 900° F. or 1000° F. For example, the lines, paths, valves,manifold, heat exchangers, seals, and ducts may be constructed ofstainless steel and may include reinforced walls. For example, 316/314stainless steel may be used to construct components of the EERS 10. Thefittings between the components of the EERS 10 may be double ferrulecompression type fittings. Suitable fittings may be available fromSwageLok®.

This is a divisional of U.S. Non-Provisional application Ser. No.17/383,900, filed Jul. 23, 2021, titled “ONBOARD HEATER OF AUXILIARYSYSTEMS USING EXHAUST GASES AND ASSOCIATED METHODS,” which is acontinuation of U.S. Non-Provisional application Ser. No. 15/929,715,filed May 18, 2020, titled “ONBOARD HEATER OF AUXILIARY SYSTEMS USINGEXHAUST GASES AND ASSOCIATED METHODS,” now U.S. Pat. No. 11,428,165,issued Aug. 30, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 62/704,556, filed May 15, 2020, titled“ONBOARD HEATER OF AUXILIARY SYSTEMS USING EXHAUST GASES AND ASSOCIATEDMETHODS,” the disclosures of which are incorporated herein by referencein their entireties.

The foregoing description of the disclosure illustrates and describesvarious exemplary embodiments. Various additions, modifications,changes, etc., could be made to the exemplary embodiments withoutdeparting from the spirit and scope of the disclosure. It is intendedthat all matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense. Additionally, the disclosure shows and describes onlyselected embodiments of the disclosure, but the disclosure is capable ofuse in various other combinations, modifications, and environments andis capable of changes or modifications within the scope of the inventiveconcept as expressed herein, commensurate with the above teachings,and/or within the skill or knowledge of the relevant art. Furthermore,certain features and characteristics of each embodiment may beselectively interchanged and applied to other illustrated andnon-illustrated embodiments of the disclosure.

What is claimed is:
 1. An exhaust energy recovery system, the systemcomprising: an inlet duct in communication with an exhaust flow path,the inlet duct having an open configuration in which the inlet duct isconfigured to divert a first portion of the exhaust gas from the exhaustflow path to a recovery flow path and allow a second non-zero portion ofthe exhaust gas of the exhaust flow path to be exhausted, the inlet ducthaving a closed configuration in which the inlet duct is configured toprevent exhaust gas from flowing to the recovery flow path; an outletduct in fluid communication with the exhaust flow path downstream of theinlet duct, the outlet duct configured to return the first portion ofthe exhaust gas from the recovery flow path to the exhaust flow path; afirst heat exchanger disposed in the recovery flow path between theinlet duct and the outlet duct, the first heat exchanger configured to:receive exhaust gas from the recovery flow path; transfer heat from thereceived exhaust gas to fluid within the first heat exchanger; andreturn the received exhaust gas to the recovery flow path; and a linkageconfigured to transition the inlet duct between the open configurationand the closed configuration thereof.
 2. The system according to claim1, further comprising a flushing assembly including a flushing port incommunication with the recovery flow path, the flushing port configuredto receive water such that the water flows through the recovery flowpath and exits the outlet duct to purge residue from the recovery flowpath.
 3. The system according to claim 1, wherein the linkage comprisesa mechanical linkage.
 4. The system according to claim 1, furthercomprising a flow restrictor disposed in the recovery flow path betweenthe inlet duct and the first heat exchanger, the flow restrictorconfigured to limit exhaust gas flow through the recovery flow path. 5.The system according to claim 4, further comprising a pressure reliefvalve having a first end in communication with the recovery flow pathbetween the inlet duct and the first heat exchanger and a second end incommunication with the recovery flow path between the first heatexchanger and the outlet duct, the pressure relief valve configured toreturn exhaust gas from the inlet duct to the outlet duct bypassing thefirst heat exchanger.
 6. The system according to claim 5, furthercomprising a second heat exchanger disposed in the recovery flow pathbetween the inlet duct and the outlet duct, the second heat exchangerconfigured to: receive exhaust gas from the recovery flow path, transferheat from the received exhaust gas to fluid within the second heatexchanger, and return the received exhaust gas to the recovery flowpath; and a manifold positioned upstream of the first heat exchanger andthe second heat exchanger, the manifold configured to distribute exhaustgas from the inlet duct to the first heat exchanger and the second heatexchanger.
 7. The system according to claim 6, further comprising: afirst control valve in the recovery flow path between the manifold andthe first heat exchanger, the first control valve configured to controlflow of exhaust gas from the manifold to the first heat exchanger; and asecond control valve in the recovery flow path between the manifold andthe second heat exchanger, the second control valve configured tocontrol flow of exhaust gas from the manifold to the second heatexchanger.
 8. The system according to claim 7, wherein the first controlvalve comprises a thermostatically controlled valve in communicationwith a temperature sensor configured to detect a temperature of a mediumassociated with the first heat exchanger, the first control valveconfigured to open in response to the temperature of the mediumassociated with the first heat exchanger being below a firstpredetermined temperature and configured to close in response to thetemperature of the medium associated with the first heat exchanger beingat or above a second predetermined temperature.
 9. The system accordingto claim 8, wherein the first heat exchanger is associated with a firstheat distribution element selected from a group consisting of an oilheater, a gearbox lubrication heater, a pump lubrication heater, a waterheater, and a heat fan.
 10. An exhaust energy recovery system, thesystem comprising: an inlet duct in communication with an exhaust flowpath, the inlet duct having an open configuration in which the inletduct is configured to divert a first portion of the exhaust gas from theexhaust flow path to a recovery flow path and allow a second non-zeroportion of the exhaust gas of the exhaust flow path to be exhausted, theinlet duct having a closed configuration in which the inlet duct isconfigured to prevent exhaust gas from flowing to the recovery flowpath; an outlet duct in fluid communication with the exhaust flow pathdownstream of the inlet duct, the outlet duct configured to return thefirst portion of the exhaust gas from the recovery flow path to theexhaust flow path; a heat exchanger disposed in the recovery flow pathbetween the inlet duct and the outlet duct, the first heat exchangerconfigured to: receive exhaust gas from the recovery flow path, transferheat from the received exhaust gas to fluid within the first heatexchanger, and return the received exhaust gas to the recovery flowpath; a flow restrictor disposed in the recovery flow path between theinlet duct and the heat exchanger, the flow restrictor configured tolimit exhaust gas flow through the recovery flow path; a pressure reliefvalve having a first end in communication with the recovery flow pathbetween the inlet duct and the heat exchanger and a second end incommunication with the recovery flow path between the heat exchanger andthe outlet duct, the pressure relief valve configured to return exhaustgas from the inlet duct to the outlet duct bypassing the heat exchanger;and a linkage configured to transition the inlet duct between the openconfiguration and the closed configuration thereof.
 11. The systemaccording to claim 10, further comprising a flushing assembly includinga flushing port in communication with the recovery flow path, theflushing port configured to receive water such that the water flowsthrough the recovery flow path and exits the outlet duct to purgeresidue from the recovery flow path.
 12. The system according to claim11, wherein the linkage comprises a mechanical linkage.
 13. The systemaccording to claim 10, wherein the heat exchanger comprises a first heatexchanger, and the system further comprising a second heat exchangerdisposed in the recovery flow path between the inlet duct and the outletduct, the second heat exchanger configured to: receive exhaust gas fromthe recovery flow path, transfer heat from the received exhaust gas tofluid within the second heat exchanger, and return the received exhaustgas to the recovery flow path; and a manifold positioned upstream of thefirst heat exchanger and the second heat exchanger, the manifoldconfigured to distribute exhaust gas from the inlet duct to the firstheat exchanger and the second heat exchanger.
 14. The system accordingto claim 13, further comprising: a first control valve in the recoveryflow path between the manifold and the first heat exchanger, the firstcontrol valve configured to control flow of exhaust gas from themanifold to the first heat exchanger; and a second control valve in therecovery flow path between the manifold and the second heat exchanger,the second control valve configured to control flow of exhaust gas fromthe manifold to the second heat exchanger.
 15. The system according toclaim 14, wherein the first control valve comprises a thermostaticallycontrolled valve in communication with a temperature sensor configuredto detect a temperature of a medium associated with the first heatexchanger, the first control valve configured to open in response to thetemperature of the medium associated with the first heat exchanger beingbelow a first predetermined temperature and configured to close inresponse to the temperature of the medium associated with the first heatexchanger being at or above a second predetermined temperature.
 16. Thesystem according to claim 15, wherein the first heat exchanger isassociated with a first heat distribution element selected from a groupconsisting of an oil heater, a gearbox lubrication heater, a pumplubrication heater, a water heater, and a heat fan.
 17. An exhaustenergy recovery system, the system comprising: an inlet duct incommunication with an exhaust flow path, the inlet duct having an openconfiguration in which the inlet duct is configured to divert a firstportion of the exhaust gas from the exhaust flow path to a recovery flowpath and allow a second non-zero portion of the exhaust gas of theexhaust flow path to be exhausted, the inlet duct having a closedconfiguration in which the inlet duct is configured to prevent exhaustgas from flowing to the recovery flow path; an outlet duct in fluidcommunication with the exhaust flow path downstream of the inlet duct,the outlet duct configured to return the first portion of the exhaustgas from the recovery flow path to the exhaust flow path; a heatexchanger disposed in the recovery flow path between the inlet duct andthe outlet duct, the first heat exchanger configured to: receive exhaustgas from the recovery flow path, transfer heat from the received exhaustgas to fluid within the first heat exchanger, and return the receivedexhaust gas to the recovery flow path; a flow restrictor disposed in therecovery flow path between the inlet duct and the heat exchanger, theflow restrictor configured to limit exhaust gas flow through therecovery flow path; a flushing assembly including a flushing port incommunication with the recovery flow path, the flushing port configuredto receive water such that the water flows through the recovery flowpath and exits the outlet duct to purge residue from the recovery flowpath; and a linkage configured to transition the inlet duct between theopen configuration and the closed configuration thereof.
 18. The systemaccording to claim 17, wherein the linkage comprises a mechanicallinkage.
 19. The system according to claim 17, wherein the heatexchanger comprises a first heat exchanger, and the system furthercomprising a second heat exchanger disposed in the recovery flow pathbetween the inlet duct and the outlet duct, the second heat exchangerconfigured to: receive exhaust gas from the recovery flow path, transferheat from the received exhaust gas to fluid within the second heatexchanger, and return the received exhaust gas to the recovery flowpath; and a manifold positioned upstream of the first heat exchanger andthe second heat exchanger, the manifold configured to distribute exhaustgas from the inlet duct to the first heat exchanger and the second heatexchanger.
 20. The system according to claim 13, further comprising: afirst control valve in the recovery flow path between the manifold andthe first heat exchanger, the first control valve configured to controlflow of exhaust gas from the manifold to the first heat exchanger; and asecond control valve in the recovery flow path between the manifold andthe second heat exchanger, the second control valve configured tocontrol flow of exhaust gas from the manifold to the second heatexchanger.
 21. The system according to claim 14, wherein the firstcontrol valve comprises a thermostatically controlled valve incommunication with a temperature sensor configured to detect atemperature of a medium associated with the first heat exchanger, thefirst control valve configured to open in response to the temperature ofthe medium associated with the first heat exchanger being below a firstpredetermined temperature and configured to close in response to thetemperature of the medium associated with the first heat exchanger beingat or above a second predetermined temperature.
 22. The system accordingto claim 15, wherein the first heat exchanger is associated with a firstheat distribution element selected from a group consisting of an oilheater, a gearbox lubrication heater, a pump lubrication heater, a waterheater, and a heat fan.
 23. The system according to claim 22, furthercomprising a pressure relief valve having a first end in communicationwith the recovery flow path between the inlet duct and the first heatexchanger and a second end in communication with the recovery flow pathbetween the first heat exchanger and the outlet duct, the pressurerelief valve configured to return exhaust gas from the inlet duct to theoutlet duct bypassing the first heat exchanger.